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Transcript of ISSue 8 // May 2013 - · PDF file// ISSue 8 // May 2013 SBM Offshore / Currents 3 Welcome to...
// Issue 8 // may 2013
SBM Offshore / Currents 1
Currents ISSue 8 // May 2013
// Issue 8 // may 2013
SBM Offshore / Currents 2
4 Champagne on ice for SBM’s firstlaunchof Generation 3 FPSO
10 New,all-in-one, state-of-the-art installer
12 FizzleoutflaringonFPSOs
14 NewSBMtechnology wins OTC 2013 award
16 One-Stop-ShopatSBMfor Semi-submersible and Tension Leg Platform technology
20 Extendingtheoperating envelopeoflarge mooringsystems
On the cover: FPSO Cidade de Paraty.
We want to hear from you: If you have comments about any of the articles in this issue or any ideas for future issues, send them to [email protected].
Currents is issued by the Group Communications Department.
Currents ISSue 8 // May 2013
4
14
10 SBM InStaller
GeneratIOn 3 fpSO
Otc aWard 2013
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SBM Offshore / Currents 3
WelcometothelatestissueofSBMOffshore’scompanymagazine.WearehappytoshareourstoriesandachievementswithourclientsandstakeholdersaswellasvisitorstoourboothattheOTCconferenceinHoustonthismonth.
Firstly,IwouldliketothankthejuryoftheOTCSpotlightonTechnologyforhonouringSBMOffshorewithoneoftheawards.Thisprestigiousaccoladeendorsesourpositionasakeytechnologyleaderintheoffshoreserviceprovidersector.Italsogivesourengineerstheindependentpraisethatmakesthemproudoftheirsuccessesandgivesthemthemotivationtocontinueinnovatingtomeettheevolvingneedsoftheindustry.
It’sbeenabusyfewmonths.WemadethenewswiththeawardbyPetrobrasforadoubleFPSOorderforoperationinthepre-saltprovinceoffshoreBrazil.Thissignificantprojectisarecordbreakerforthecompany,theFPSOsareamongstthelargesteverbuiltbySBMOffshoreandalongwithCidadedeParatyandIlhabelarepresentthesuccessfullaunchofournewGeneration3FPSOs,buildingonourtrustedperformanceandunrivalleduptime.
Enjoythismonth’sissue.
Bruno Chabas CEOSBMOffshore
Welcome
20
12
16
larGe MOOrInG SySteM
SeMI-SuBMerSIBle and tenSIOn leG platfOrM technOlOGy
fIzzle Out flarInG On fpSOS
// Issue 8 // may 2013
ChampagneoniceforSBM’sfirstlaunchofGeneration 3 FPSO
SBM Offshore / Currents 4
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SBM Offshore / Currents 5
ThingsaredefinitelybuzzingrightnowontheBrazilianfrontforSBMOffshore.The
companyhasinhandnofewerthanfourofthemostcomplexFPSOprojectsyetseenbytheoilandgasindustryanywhereintheworld.Allofthesebilliondollarplusfloatingproductionvesselsaresettohelpdevelopthecountry’shugedeepwaterfieldsintheprolificpre-saltSantosbasin.
Start-upofthefirstofthem-CidadedeParaty–isimminent.Thishighcapacityvesselwastowedouton16ApriltotheLulaNordestefieldfromitsfinalintegrationbaseattheBrasfelsyardinAngradosReis.“NowwehavetwomoremilestonestoachievebeforetheendofJuly,”saysSBM’sProjectManagerPeterdeHaas.
“Withthe28-hourtowtolocationcompleted,wewillhookupthe24-linemooringsystemandrisersonascheduletoachievefirstoilbytheendofMay,”hesays.“Thenwewillstopflaringtheassociatedgasoncewegetthecompressionsystemsupandrunning.
WhileallthisisgoingonforParaty,elsewhereintheworldthesecondofSBM’squartetofleading-edgeFPSOsistaking
shapeatyardsinChinaandBrazil,wherehullconversionandtopsidesconstructionrespectivelyaretakingplace.
ThisisCidadedeIlhabela-withaprocessingcapacity25%higherthanParaty’s120,000bpd,andthelargestFPSOthecompanywillhaveeverbuilt.AsProjectManagerAlexBrigdenpointsout,itisalsothecompany’smostglobalproject,withprojectmanagementcentredaroundateaminSchiedamintheNetherlands.
Andasifthispairwasnotenough,inMarchPetrobrasconfirmeda$3.5billionfast-trackfollow-onordertoSBM.ThiswasfortwomorefloatingproductionunitsofthesamescaleasFPSOCidadedeIlhabela.Theunits-knownasAlphaandBeta-aredestinedfortheLulaAltoandLulaCentrallocationsandneedtobepushedaheadatanunprecedentedlyfastpacetoperformtheirrolesinPetrobras’grandplanforthepre-saltregion.
TheorderfromPetrobrasforAlphaandBetaisthelargestordereverwonbySBMOffshore.Itwillkeepthecompanyanditscontractorsandsuppliersfullyoccupieduntildeliveriesattheendof2015andearly2016respectively.
TheonlywaysuchatargetcanbeachievedisforSBMtobuildthenewvesselsas“carbon-copies”ofIlhabela,squeezingeverylastadvantageoutofthatcloningprocesstoimproveefficiencyandsavetime.
SBM’shugeprogrammeofworkforPetrobrashasalsosparkedseveralothermajorinitiatives.ThefirstoftheseistheBrasayard.
Asfarbackas2011thecompanyembarkedonaplantosetupaconstructionyardinBrazilthatitcouldcallitsownandbesureitsprojectswouldgettoppriority.Intoday’soverheatedconstructionclimateinthecountrythereistheconstantdangerofbeingover-shadowedinayardthatisalsobuildingforotherclients.
TheBrasayardalsoprovidesahugelyvaluablelocalcontentaspectandundoubtedlyhelpedclinchtheAlpha/Betacontract.
AfurtherinitiativebySBMOffshoreisashiftinemphasistoChinaforconversionofthetankerhullswhichprovidethebasisoftheoilandgasprocessingandstorageunitsthatareleasedandoperatedbySBM.
FPSO Cidade de Paraty
Location: BM-S-11 block, Lula Nordeste Field, Partners in Block: Petrobras Netherlands B.V. 65.0%, BG Group 25.0%, GALP 10.0%. Lease & Operating Consortium: Queiroz Galvão Óleo e Gás 20.0%, SBM Offshore 50.5%, Nippon Yusen Kabushiki Kaisha Group 17.5%, Itochu Group 12.0%
FPSO Cidade de Ilhabela
Location: BM-S-9 block – Sapinhoá Field, Partners in Block - Petrobras (45%), BG E&P BRASIL LTDA (30%) and REPSOL YPF BRASIL S.A. (25%), FPSOs will be owned and operated by a Joint Venture company owned by SBM Offshore with other partners including Queiroz Galvão Óleo e Gás S.A.(QGOG).
FPSOs Alpha & Beta
Location: BM-S-11 Block, Lula Field, Partners in Block: PETROBRAS (65%), BG E&P Brasil Ltda. (25%), and Petrogal Brasil S.A.(10%). FPSOs will be owned and operated by a Joint Venture company owned by SBM Offshore with other partners including Queiroz Galvão Óleo e Gás S.A.(QGOG).
// Issue 8 // may 2013
SBM Offshore / Currents 6
Also,forthefirsttimeinitshistory,SBMismovingtoconversionofapairofdouble-hulledVLCCtankersforAlpha/Beta,insteadofthesingle-hulledtankerswhichhavebeenitsfeedstockuntilnow.
BackinTheNetherlands,SBM’sofficeinSchiedamisattheheartoftheseGeneration3projectsforBrazil.“Wearecarryingtwoandahalfprojects-Paraty,IlhabelaandhalfthescopeforAlpha/Beta,”saysYvesPaletta,ManagingDirectorofSBMSchiedam.TheAlpha/BetaprojectisexecutedjointlywiththeSBMOffshoreExecutionCentreinMonaco.
“It’samajortransformationandtodeliverthesecomplexprojectswe’remakingsurewearelearningasfastaswecanfromParatyandembeddingthelearningsintoIlhabelaandAlpha/Betaintermsofefficiency,safetyandlocalcontent.Wearegoingforascheduleof31-33monthsforAlpha/Beta,”hesays,“whichisanextraordinaryachievementmadepossiblethankstothecarboncopyeffectwithCidadedeIlhabela.”
SchiedamcomesfromanengineeringbackgroundratherthanEPCroots,soalongwithOperationsDirectorJohnSchubert,Palettaislookingto“transformthecompanytobecomeaworld-classEPCentity.
“Andwearedoingthisonthebackoffourofthebiggestprojectsthegrouphaseverundertaken,”hesays.“Wearelearningasfastaswecananddoingitreasonablywell.”
Double hull takes centre stage
Therecentmega-contractforAlpha/BetahasresultedinanotherfirstforSBM-theconversionofadouble-hullVLCC
tankertoserveinitsownfleetofFPSOs.
“Thestockofsinglehulltankersforconversionhasliterallydriedup-therearenosuitablehullsleftonthemarket,”saysMikeWyllie,CTO.“Soweandourcompetitorsareforcedeithertobuildnewhullsortostartusingdouble-hulledtankersforourconversions.”
“Wedon’tseeitasabigissue,”hecontinues,“butit’sachangethattheAlpha/Betaprojectintroduces.Wehaveobtainedtwoverygoodidenticalsistershipstostartfrom,anddouble-hullconversionsaresomethingwe’vestudiedalotinrecentyears.”
TheconversionsofAlphaandBetawillrunalmostinparallel,virtuallyasingleprojectratherthantwo.
InthepastthecompanyhasconvertedaSuezmaxsizedouble-hull-forWoodsidePetroleumforitsCossack,Wanaea,LambertandHermesfields-butthisisthefirsttimeithasdonesoatthislargersize,andforitsownfleet.
IlhabelaProjectManagerAlexBrigdennotes:“fromaconversionpointofview,double-hulledtankersdon’toffermanyhelpfuladvantagesanddefinitelyrepresentanincreaseinthechallengecomparedwitholdermildsteelsingle-hulltankers.”
“Youendupwithalotofvoidspacesthathavetobeactivelymaintainedandlargertransversespanswhicharemorecomplexforsupportingmodules.Alsotheygenerallyhavealotmorehightensilesteel.Althoughthisdoesnotaffectoverallstrength,fatiguelifegetsusedupmorerapidly,soyouhavetodomoretocounterthat.”
Double-hullcarriersarealsoalittlelargerthantheirsingle-hullequivalents,sothemooringsystemsonAlpha/BetawillneedmodificationcomparedwithIlhabela.AndtheextradeckspacewillnotbeofasmuchvalueasitmighthavebeenifIlhabela’stopsidedesignwerenotbeingclonedforthenewunits.
Brazilian operations
AswellasbuildingitsnewfleetofGeneration3vesselsforBrazil,SBMischargedwithoperatingtheminthefieldfortheirfullproductionlife.
ThisistheresponsibilityofitsfleetoperatingcompanySBMProductionContractors(PC),whereMikeWyllieiscurrentlyactingasManagingDirector.
DescribingthebiggestchallengesforPChesays:“alotofthemovetothe‘Generation3’FPSOsthatwehavefortheSantosbasin,is
FPSO Cidade de Ilhabela - Artist’s impression
// Issue 8 // may 2013
arounduppingourgametobereadytomanupallthesenewunitswithcompetentpeople.With80%ofthecrewrequiredtobeBrazilianfromdayoneweneedtohirealotofBraziliansandwe’relookingatthingslikestrengtheningourtrainingfacilitiesinthecountry.”
Therewillalsobegeographicalimplications.“WeopenedournewshorebaseofficeinSantosinmid-April,”saysWyllie.Withthestart-upofParatythiswillbeginlifeasasatelliteofSBMPC’sheadquartersforBrazilianoperations,inMacaé.
Nextyear,asIlhabelastartsup,theSantosofficewilldoubleinsize.“Later,whenyouaddAlpha/Beta”,saysWyllie,“thewholecentreofgravityofouroperationsinBrazilwillmovetherefromMacaé.
“Wewillbeoperatingthefourbiggestvesselsinourfleet,allside-by-side,alloutofSantos,”hepointsout.“That’snearly600,000bpdofproductioncapacityandaverysignificantdailyrevenuecomingthroughthatoffice.”
A first for SBM in China
ForIlhabela,SBMhasstruckupanewrelationshipinChina.IthaschosentheChengxishipyardinGuangzhoutoconvertthehull.“Thisisthefirsttimewe’vetakenanFPSOtoChina,”saysIlhabelaProjectManagerAlexBrigden.
Therelationshiphasbeenshapingupwell,andhasexpandedmorequicklythanoriginallyplanned.“Thereisaveryopenstylefromthemanagement,”saysBrigden.
“WeputinalargeteamtosupporttheyardandbringthemuptospeedandwecanseeparallelsfromwhenwefirststartedwithKeppelinSingapore,”hecontinues.“Theyaregoingtobeagoodassetforusinthefuture.”
HecitesanexcellentexamplefromtheverystartoftheIlhabelaconversion.WhentheconversionvesselarrivedinChinaandwasgivenitsclose-upsurvey,itwasclearthatthelevelofcorrosionintheupperdeckcalledforsubstantialreplacementwork.
“OurcontractorisarepairyardintheCSSCgroup-China’slargestshipbuilderandthesecondlargestintheworld,”saysBrigden.“Nearbythegrouphasanewbuildyardaswell.
“Soweseizedtheopportunitytohavetheupperdeckreplacementdoneasnewbuild.Wedidthesamewiththeaccommodationbecause
itdidn’tquitemeetBrazilianregulations.
“Itwasourgoodfortunetohaveselectedaconversionyardthatwaspartofthisbiggergroup”,hecontinues.“NowthishasbecomeathemeforAlpha/Beta:thatwemakeuseofbothyardsandtheirskillsets,withsomenewbuildingandsomeshipconversion.SowhatweareactuallyproducingisanFPSOasahybrid,andthisisnewforSBM.”TheconvertedIlhabelahullwillleaveforBrazilinthemiddleof2013.
TheChineseyardhasalsoachievedanadmirablesafetyrecordofmorethanfivemillionmanhourssofarwithoutalosttimeincident.Thisis
SBM Offshore / Currents 7
Riser balcony - FPSO Cidade de Ilhabela
FPSO Cidade de Ilhabela - April 2013
// Issue 8 // may 2013
SBM Offshore / Currents 8
comparablewithworldnormsandanexcellentachievement.
“Itisdifficultbecausetheyardhadnotworkedunderoffshoresafetystandardsbefore,andhadnothadthatmanyinternationalcustomers,”saysBrigden,“buttheyimproveprogressively,weekonweek.”
Brazil’s new yard
Inlittlemorethanayear,SBMhassetupafabricationyardinNiteroi,justacrosstheBayfromdowntownRio,dedicatedtothecompany’sownneeds.
UndoubtedlytheBrasayardwasasignificantfactorinhelpingwinthecovetedAlpha/Betacontract.“WithoutBrasawewouldn’thavebeeninapositiontowin,”saysPhilippeLevy,whoisactingGeneralManageroftheyardinadditiontohisroleasheadofSBMBrazil’sofficeinRio.“Petrobrasgaveustheawardbecausewehadmorecapacityforlocalcontent”.
Developedin50:50partnershipwithBrazil’sSynergygroup,theyardhasbeencreatedfromaderelictyardthatstoodempty18monthsago.“Weaimtobeseenasayardthatdeliversontime,”saysLevy.“It’sthemarkofSBMandwewanttobuildonthisreputation.”
ThefirstprojectforBrasaisIlhabela:“theyardhasbeenupandrunningsinceJulylastyear”saysProjectManagerAlexBrigden,“anditisbuildingtenmodulesweighingatotalofabout12,000tonnes”.Over1000employeesaretherenowandthatwillriseto2000peopleinthecomingmonths.
ImmediatelyoncemoduleconstructionworkforIlhabelaisfinished,Brasawillgostraightintofabricationoftenofthe18modulesrequiredforAlpha/Beta,startingnextyearandrunningtotheendof2015.
“Ourintention,atleastinitially,wastouseahighproportionofsub-contractorsforworkintheyardandmovetoagrowingproportionofdirectemployees,”saysBrigden.“Thatprocessisgoingwell,andwearefindingthattheproductivityofemployeesunderdirectmanagementisexcellent,whichisaverypositivedevelopment.”
TheRioarea,andespeciallyNiteroihasagoodpoolofwell-trainedlabourtochoosefrom,hepointsout.“Anditisimportanttoemphasisethataswellascompetitivesalaries,Brasaalsoofferslong-termprospects,withIlhabelaandotherprojectscomingthrough.”
Paraty leads the way
Asfirstofthefarmorecomplex‘Generation3’breedofFPSObeingbuiltbySBMinBrazil,CidadedeParatyispioneeringthepathnowbeingfollowedbyIlhabelaandAlpha/Beta.AlthoughthosethreelaterunitswillnotbeclonesofParaty,theywillbenefitgreatlyfromthelessonslearnedthere.
SummarisingtheParatystory,ProjectManagerPeterdeHaasspeaksofanaggressivestarttotheproject,pushingengineeringandprocurementtogainasmuchfloat-timeaspossibleinthe36-monthoverallschedule.ThiswasfollowedbyaperiodofforcemajeuredelaysandsetbacksduringthefabricationworkinBrazilwhicheliminatedmuchofthatfloattime.
AfterajointalignmentmeetingwithPetrobras,BrasfelsandSBMOffshorethepacepickedupsteadily,finishinginahighlysatisfyingpushtoachievethesail-awaydateon16thApril.
“Byverythoroughpreparationoftheintegrationphase-fromthemomentthelasttopsidemodulewasplacedonthevessel,tothemomentitcouldleavethequayside-wehavemanagedtocompletethatworkinfiveanda
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halfmonths,”saysdeHaas.“EveninanexperiencedSingaporeyardthatwouldbequiteaneffort,”heremarks.“Itwascertainlychallenging,butveryrewarding.”
“ItisquiteajumptoGeneration3,”saysdeHaas,“ParatyreallyisthemostcomplexunitdeliveredbySBMtodate”.Aswellasvesselsize,“thecomplexitycomesinthegasconditioningandcompressionsystems,”hepointsout.“ItisthefirsttimewhereweremoveCO2 withmembranetechnology,andthefirstwherewedodeepdehydrationofgas-removingthewaterwithmolecularsieves.Also,weprovidegasandCO2 compressionupto550bar-attheforefrontoftheindustry.”
ModuleconstructionstartedinMarch2011,sixteenmonthsbeforethehullarrivedfromitsconversionbyKeppelinSingapore.Therewere15topsidesmodules,weighingatotalof12,500tonnes,withtwelveofthembuiltinBrazil-sixbyBrasfels,fourbyEBSE,andtwobyEnaval.
“ThedifficultyhereinBrazil,”saysdeHaas,“withsomuchworkbeingpushedintothiscountry,therearetremendousconstraintsonresources,especiallyskilled
manpower.”Inaddition,therewerethreeweeksofstrikesattwoofthesitesinMaylastyear.
AmongtheverypositivesurprisesforSBMwastheliftingcampaigntoplacemodulesonthevesselatBrasfels.“Withthesecomplex,congestedunitswehaveastruggleforplotspace,”saysdeHaas.“Yetalltwelveheavyliftswentverysmoothly,withoutanysignificantclashes.”
Amajorrequirement,successfullymetontheParatyprojecthasbeentoachievetherequired65%valueofBraziliancontent.“Wehavetakenthisseriouslyfromdayoneandevenexceededthistargettoreach68%,”saysdeHaas.
“ItisveryimportanttostaffupwithBraziliannationalsandtohaveagoodpresenceincountry.WehavealsoputquitesomeenergyintoadjustingourdesignsinordertobuyBrazilian.”
ItwascertainlyaveryfruitfulstrategybySBMtoestablishanofficeinRio-headedbyGeneralManagerPhilippeLevyaslocalcontentchampionandkeyclientcontact.Thishasevolvedtoprovideareallystrongsupportingfunctiontothecompany’sprojectsinBrazil.Itdealswitheverythingfromvital
topicslikelogisticsandcustomsclearancetolocaltransportandaccommodation.
Asforthechallengeof coordinatingaglobalprojectlikeParaty,deHaasreflects:“thekeyistoestablishpersonalcontactsbetweenkeyindividualsatallsites”.
HeunderlinesthevalueoftheSBMcompanyslogan“workasone”,introducedwhenChiefExecutiveOfficerBrunoChabascameonboardearlylastyear.“Thatsloganreallyworks,”hesays.“Itisdefinitelyimprovingresults,anditisalsoinstillinganiceworkingatmosphere.”
AmongthelessonsofParatypassedontoIlhabelaanimportantoneconcernsmaterialshandlingonabigcongestedtopsideandthescopeforoptimisinglayoutandergonomicstoimprovethat.
Asforthevessel’sreadinessatitsmid-Aprilsail-away,SBMSchiedam’sOperationsDirectorJohnSchubertremarksthat“wehadconsiderablecarryoverworkduetodelaysinengineeringandthenequipmentdelivery;however,bythetimeofherdeparturewehadachievedagoodbalancewithaclienthappytohavethevesseloffshoretostarthook-upofmooringsandrisers.”
SBM Offshore / Currents 9
FPSO Cidade de Paraty at quay side at Brasfels
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What’sbetterthanonestate-of-the-artinstaller?Quitesimply‘two’.
TowardstheendofthisyearSBMOffshorewilladdanotherhigh-techvesseltoitsinstallationfleet,givingSBMOffshoreareasontobeproudandclientsareasontobecontentthatshewillbeupandreadyforservice.
ThenewlybuiltSBMInstaller(SI)willraisethebarinhigherstandardsforthenewgenerationofDiveSupport&Constructionvessels.Herdesignwasinresponsetoacallfromclientsforincreasedversatilityincapacityanda‘do-it-all’vesselinordertoeliminatetheneedforseparateelementssuchasadivingsupportandacrane,whichnormallyhavetoaccompanyaninstaller.SBMengineersdrewon40yearsofexperienceinoffshoreinstallation,divingworksandconstructionactivitiesworldwideinallkindofwaterdepths.Theconstructionoftheinstalleriscurrentlytaking
placeintheKeppelSingmarineinSingapore.
WhatdifferentiatestheSIfromthecompetitionisherexclusivecombinationofafullyintegratedsaturationdivingsystemwithstrongconstructionandchainhandlingcapabilitiesinaDynamicPositioning(DP)classIIIvessel-withthehigherclassofredundancy-givingherunrivalledversatilityandefficiencywithinasafeworkingenvironment.
The key components
The111-metrevesselisequippedtocarryoutoffshoreconstructionandinstallationworkinwaterdepthofupto1,700metreswitha275tSWL(SafeWorkingLoad)knuckleboomcraneandanactiveheavecompensated150tSWLwinch.Tohandleandstoresafelylonglengthsofmooringlegs,sheisalsoequippedwitha200tSWLdouble-drumwinchandfourlargestorageareascalledchainlockersof135m³each.
Thepatenteddouble-deckconcept,alreadytestedandprovenontheNormandInstaller,providesalargestorageandconstructionareaontheupperdeckwhilekeepingtheconventionalmaindeckunobstructedtorunchainsorwiresoverthesternundertension.ArnaudAnnebicque,OperationsManageroftheNormandInstaller,saysthatclientsareunanimousintheircomments“Thedoubledeckconceptbringsarealplus,SBMmadeasmartdesign,whichiswellfittedtodeepwaterconstructionworks.”
Twotypesofdivingsystemsarepossibledependingonthewaterdepth.Upto50m,aconventionalairdivingsystemisoperatedoverthestarboardsideofthevessel.Fordeeperdivingoperations,asaturationdivingsystemallowsworkupto300m.Thedeepwaterdivingisaveryspecificandconstrainedactivity.Thediversstayconfinedinthepressurised
New, all-in-one, state-of-the-art installer
SBM Offshore / Currents 10
TheSBMInstallerhas
reached2.4 million man hoursduringtheconstructionphase
withoutaLostTime
Incident
Three living chambers saturation diving system
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SBM Offshore / Currents 11
atmosphereduringtheentiredivingcampaignupto28days,plusadecompressionphasethatcantake10to12daysdependingonthedepthandpressure.
TheSBMInstallersystemhasa12-mancapacity,evenifoneofthethreechambersisundergoingmaintenance.Eachchambercanbepressurisedindependentlyallowingseveralteamstoworkatdifferentwaterdepths.
Incaseofemergencyaspecifichyperbariclifeboatwillsafelyevacuatethedivers,whilemaintainingthepressurisedenvironment.
Operationswillbesupportedbytwoheavywork-classRemotelyOperatedVehicles(ROVs).BothROVscancarryoutobservationandinterventionworkstoawaterdepthof3,000m.
Safety,versatilityandredundancyarethethreekeyconceptstohavedriventhedesignofSBMOffshoreinstallationvessels.
Thedouledeckconceptallowspreparationforfutureoperationswhiledeployingthesubseaequipment.However,thisbenefitcanmostlybequantifiedintermsofSafety,withanexcellentsafetyrecordclockedupontheNormandInstallerasproof.Ofnoteisthefiringlinelocatedonthelower
deckwherenopersonnelareallowedduringsubseadeploymentoperations.
Thevessel’smanyadvantages:beinganAnchorHandlingVessel(AHV),aDivingSupportVessel(DSV),aconstructionvessel,andalargedeck(thankstotheflatupperdecktoeasilystore,mobilise,anddemobiliseallkindofequipment)givesthevesselgreatversatility.Thecombinationofallthesefeaturesmeansshecanperformcomplexanddiversifiedtaskseliminatingtheneedtomobiliseothervessels.Thetwocranescanbeusedtoplaceequipmentoverboard,toinstall,thentransfertheloadtooneofthedeepwaterwinches.Theheavecompensatedwincheisutilisedifslowmotionisrequiredduringlandingphase;orthedoubledrumswinchisusedifthelandingspeedisnotthatcriticalfortheoperationinhand.
Finally,redundancyofequipmentisfundamentaltobothkeepingthevesseloperationalinthecaseofequipmentfailurebutalsoinallowingthecombinationoffunctionstosavetimeandincreaseefficiency.
Twoyearsfollowingcontractsignature,thevesselisnownearingcompletionandthephaseofheavytestingandcommissioning–includingseatrials–iscurrently
takingplace.OncedeliverytakesplaceinSingaporethissummer,theSIisscheduledtostartworkingonprojectsinQ42013.
HerfirstareaofoperationwillbeWestAfrica,whereSBMOffshoreoperatessixFPSOs.Thentheworldisheroyster.Hertransitspeedandreducedconsumptionwilloptimiseherfastredeploymentallovertheworld,includingBrazil,NorthSea,MiddleEast,SouthEastAsiaandtheGulfofMexico.
TheSBMInstallerwillinstalloffshoreAngolatheFPSON’Goma,theformerFPSOXikomba.ThislifeextensionprojectwasmanagedbytheKualaLumpurexecutioncentreinliaisonwiththePAENALyard.Thefabricationandintegrationyardisinchargeoftwoprocessmodules-aclearexampleoftheseamlessinterfacefulllifecycleserviceprovidedbySBMOffshore.
Versatility,redundancyandsafetyachievinganincreaseinefficiencyarethemainbenefitsoftheSBMInstaller:theseenablehertooutpaceallothervesselsinhercategoryandallowinmostcasesforthemobilisationofonlyonevesselratherthanseveraltoexecutethecompletescopeofwork.
SBM Installer close to completion at Keppel Signmarine
Key facts
lOa 111.2 m
draft ranging from 5.50m to 7.70m
cruise speed 12 kts
Max bollard pull 110t
accommodation 100 paX
diving system 12 men
Offshore crane capacity 275t
Winches 200t double drum + 150t heave compensated
Storage space 1200m²
// Issue 8 // may 2013
SBM Offshore / Currents 12
Whatiftomorrowgasflaringwasevenmorerestricted?AnticipatingthisscenarioSBMOffshoreteamedupwithCompactGTLandfollowingfouryearsof
collaborativedesignandengineeringdevelopment,thetwocompanieshavecomeupwithauniquesolutionforFPSOs,exclusivetoSBMOffshore,whichcouldchangethewayoilandgascompaniesviewnewoffshorefielddevelopments.
Withoilfielddiscoveriesincreasinglylocatedinremoteanddeepwaterstheproblemofassociatedgasdisposalhasbecomeanexpensiveandtrickydilemmaforthebigplayersintheindustry.Usingpipelinestomarketisprohibitivelycostlyforstrandedfieldswherethereisnoinfrastructure.Otheralternativesincludeelectricitygenerationorgasre-injectionintothereservoirorflaring,whichisbecomingincreasinglyofflimitsinsomepartsoftheworld,evenintemporarysettingssuchasforEarlyWellTest(EWT)work.Theindustryiscallingforoiloperatorstoreduceflaringbynaturalgasassociatedwithoilproductionbyafurther30%by2017–equivalenttotaking60millioncarsofftheroad.
Aviable,industryapproved,solutiontoeliminateflaringisofferedbyUK-basedcompanyCompactGTLwhohavedesignedanadaptationofconventionalGastoLiquid(GTL)technologyforsmallerscaleapplications,toaccommodateoperationswhereasmallvolumeofgasisproduced.
ForeseeingthepotentialtoadaptingthispioneeringtechnologyforspecificuseonSBMOffshore’sFPSOs,thecompanysignedanexclusivecommercialagreementlatelastyearwithCompactGTLtocollaborateexclusivelyonoffshoreprojects.TogetherweareadvancingtheGTLtechnologyintandemtofurtherdevelopthetechnologicaledgeofourFPSOs.Acommercialdemonstrationplant(Figure1)providedbyCompactGTLhasbeeninoperationonshoreinBrazilsinceDecember2010,fundedbyPetrobras,furthervalidatingtheimportanceofthistechnology.
Mini-size GTL plants
ConventionalGTLplantsareknowntobeverylargestructures,thePearlGTLprojectinQatarissaidtobethesizeof450footballfields,butnowSBMOffshorewithourpartnerproposeanewsmallerscalesolution,enablingtheGTLplanttofitonanSBMOffshoreFPSOvessel.
Fizzle out flaring onFPSOs
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SBM Offshore / Currents 13
ThisagreementwithCompactGTL–representsaworld-firstforsuchvessels.MikeWyllie,ChiefTechnologyOfficeratSBMsays“CompactGTLhasbroughtthetechnologyto
apointwherewebelieveitcanbeintegratedrelativelyeasilyontoanFPSO.FromourviewpointwearelookingactivelyatanumberofwaysofincreasingthecomplexityofconvertedFPSOs.Wetargetthetop-endofthemarketandGTLisonewayofextendingourcapabilityintomorecomplexunits.We’restartingsmall,usingitforassociatedgasdisposal–wethinkthat’sagoodwaytogetitoffshoreandgainexperienceinoperatingafloatingfacilitywithGTLcapabilities.”
What are the benefits of GTL to FPSO users?
Foroffshoresolutionsthegastoliquidtechnologysolvestheproblemoftheassociatedgas–theoffshootofoilproduction–whilstcreatingadditionalsyntheticcruderevenuesfortheoperator.Thisrepresentsasignificantbenefitbyturningwhatwasoriginallyaliabilityintoanassetandatthesametimeeliminatingtheneedforflaring.DeployingaGTLplantonthedeckofanFPSOrepresentsaparadigmshift;firsthanditbecomesaprojectenabler,allowingoilcompaniestoproceedwithfielddevelopment,wherepreviouslyitwasnotcommerciallyviable.AccordingtoIainBaxter,DirectorofBusinessDevelopmentatCompactGTL“withsmall-scaleGTL,becausetheendproductissyntheticoilwhichcanbeeasilymingledwiththeconventionalcrudeoil,theoilcompanyhasasingle,easilyaccessiblemarketfortheproduct,requiringnoseparatestorageortransportation,irrespectiveoftheoilfieldlocation.”
BottomlineforoiloperatorsisthatthenewtechnologyincorporatedtoanFPSOincreasestheproductivitywhilstaddressingthelegislativeissueofflaring.CompactGTLChairman,TonyHayward,says“CompactGTListheclearleaderinacurrentlyuntappedsectoroftheoilandgasindustry,helpingtochangetheperceptionofGTLthroughprovidingagame-changing,economicallyviablesolutiontotheglobalproblemofgasflaring.”
Itisalogicalstepforthetwocompanies,bothleadersintheirrespectivefields,havingsuccessfullyworkedtogethersince2008.Byconsolidatingtheirrespectivestrengthsandexpertiseforthemarketingandexecutionofprojectsinvolvingassociatedgaschallengesforoffshoreoilfieldstheyrepresentapowerfulduointheexpansionofthesector.TheoptimisedFPSOwithanintegratedGTLplantcanbeappliedtoanEWTserviceoronafullfielddevelopment.MichaelWyllieexplains“InanEWTcontext,thistechnologyisperfect.Youcanhopfromfieldtofieldwithoutflaringgas.Wehavedoneextensivestudiesin-houseforsuchavessel.NowthenextstepistogointoFEEDstudywithaclientforaspecificapplicationineitheranEWTorfullfielddevelopmentcontext.”
WithanexclusiveagreementinplaceSBMOffshore,theleaderinthesupplyofleasedFPSOs,increasesitscompetitiveadvantagebyofferingtheworld’sonlyfloatingproductionsystemwithafullyintegrated,modularGTLsolutionallowingforacapacityof25MMscf/d,upto32,000bbl/dcrudeproductionand2,000bbl/dGTLliquidsproduction.MikeWyllie,comments“SBMOffshoreandCompactGTLprovidecomplimentaryexpertise,andbycombiningthiswehavebeenabletodevelopanexcitingnewFPSOproduct,whichwillbeaveryattractivesolutionforassociatedgasdisposalinultradeepwaterfields”.
NicholasGay,ChiefExecutive,CompactGTLsaid:“CompactGTLisdelightedthatwehavebeenabletocementourlongstandingrelationshipwithSBMOffshore.Itisaworldclasscompanyand,combinedwithourexpertiseindeliveringtheworld’sfirstcommercialscalemodulargastoliquidssolutionforassociatedgas,willhavesignificantimpactontheoffshoreoilfieldappraisalanddevelopmentsector.”
The modular gas solution
Figure 1
Artist’s impression of the riser balcony
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SBM Offshore / Currents 14
SBMOffshoreisdelighteditsendeavorstostepupthepaceoftechnologyhaveresultedinsteppinguptothepodium.
DuringtheannualOffshoreTechnologyConference(OTC)thismonthinHouston,SBMOffshorewilljointheline-upofproudwinnersfortheprestigious‘SpotlightonNewTechnology’award.Thecompany’sinnovativeproduct,theDrillingRiserTripSaver™isamong15technologiestoberecognised–havingfulfilledthejury’soverallrequirement‘toprovidesignificantimpactforoffshoreexplorationandproduction.’
Usingarail-mountedtransportsystem,whichrelocatesasuspendeddrillingriserwithadrillingrisertensionersystemandsurfaceblowoutpreventerin-place,theDrillingRiserTripSaver™isaninnovativeapparatusandmethodfordrillingmultiplesubseawellsconsecutively,whilesavingtime,moneyandreducingriskbyavoidingremovalofthesuspendeddrillingriserfromthewellbay.
TheSBMOffshorededicatedteaminHoustoncontributedtothetechnology’sdesigndevelopmentandRandyJordan,VicePresidentFloatingProductionSystems,whoisattendingOTCtomeetwithindustryplayers,developedtheconceptualdesign.
Lastmonthwhenthewinnerswereannounced2013OTCchairpersonSteveBalintcongratulatedwinnersontheirachievements“Theinnovationshownbythisyear’sSpotlightAwardrecipientsdemonstratesthetypeofingenuityandforwardthinkingthatisadvancingtheindustrytonewlevelsofsafety,productivity,andefficiency.”
Winning technologies were selected based on the following five criteria:
1. New:lessthan2yearsold
2. Innovative:original,groundbreaking,andcapable ofrevolutionisingtheoffshoreE&Pindustry
3. Proven:throughfull-scaleapplicationorsuccessful prototypetesting
4. BroadInterest:broadappealfortheindustry
5. SignificantImpact:providessignificantbenefits beyondexistingtechnologies
New SBM technology wins OTC 2013 award
The Drilling Riser Trip-Saver is a winner of
the 2013 OTC Spotlight on Technology
Award. Using a rail-mounted transport
system, which relocates a suspended drilling
riser with a drilling riser tensioner system
and surface blowout preventer in-place, the
Drilling Riser TripSaver™ is an innovative
apparatus and method for drilling multiple
subsea wells consecutively, while saving
time, money and reducing risk by avoiding
removal of the suspended drilling riser from
the well bay.
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SBM Offshore / Currents 15
ThegrainoftheideafortheTripSaversystemwasplantedinmid-2011andinspiration
wasfosteredplayingaroundwithfeedbackfromclients’inefficienciesanddelaysoccurringduringtheiroperations.Thisledtheteamontheinventiveroadtothetechnology’sdevelopmentanditwasfirstintroducedinApril2012inaclientbidrequestforadry-treeTensionLegWellheadPlatform(TLWP)applicationinWestAfricain800metreswaterdepth.
Thismethodofhandlingandtransferringahighpressuredrillingriserfromonewelltoanotheronadry-treeTLWPhasnotbeenpreviouslydeveloped.Thismeetsthemostimportantoftheaward’sfivecriteriathatthetechnologybeinnovativeandcapableofrevolutionisingtheoffshoreE&Pindustry.TheDrillingRiser Trip-Saver™representsasubstantialtimesavingsduringthedrillingcampaignbyalleviatingtheneedtorecoverandredeploythedrillingrisermultipletimesaswellassubstantiallyreducingthewearandteartothedrillingriser,thussavingmoneyaswell.Additionallyandmostimportantly,itresultsinreducedsafetyriskbyminimisingdroppedobjecthazardconcernsduringsimultaneousdrilling&productionoperationswhilelivewellsareinproduction.
Aswithallnewtechnologyconcepts,theirsuccessisjudgedbytheideasinactionandiftheyactuallywork.ThetechnologybehindtheDrillingRiser Trip-Saver™hasbeenprovenbasedonafullscaletestofsimilartechnologydevelopedandcurrentlyinuseonthreedeepwatersemisubmersibledrillingunitssubseaBOPHandlingsystems.
ItisnotthefirsttimeSBMOffshorehasreceivedthisprestigiousaward–previouswinninginnovationsare:
Electrical Swivel – 2011
Cool Hose – 2011
LNG Toroïdal Swivel – 2007
MikeWyllie,ChiefTechnologyOfficercongratulatedtheteamonthisyear’swinsaying“itclearlyshowsthevaluablecontributionthatSBMmakestotheindustryasaTechnologyLeader.”
TheDrillingRiserTrip-Saver™hasgeneratedagreatdealofinterestduetotheadvantagesitoffers.RandyJordan,VicePresidentFloatingProductionSystems,isindiscussionwithseveralpotentialclientswhoareinterestedinadoptingittoimprovetheiroperations.“WearedelightedwiththeSpotlightaward,whichwillfurtherincreasethelevelofinterestinourproduct,”hesays.
OneofSBMOffshore’sclientscommented“whenconductingsimultaneousdrillingandproductionoperationsourcompaniesHSEpolicymandatesthatanyequipmentliftsinexcessof15mtrequireshut-inofliveproducingwellsduetodroppedobjecthazardswithinorabovethewellbay,thissystemremovesthedroppedobjectriskbyalleviatingtheneedtorecoverandre-deploythedrillingriserincloseproximitytoliveproducingwellsinadditiontotheassociatedproductiondowntimeduetowellshut-in&startupconcernsassociatedwithwellfluidscooldownandproductionstart-upcomplicationsthatoccuraftercool-down.”
SummeduptheDrillingRiser Trip-Saver™diminishesmostofthenegativespreviouslyexperiencedbyoperatorsofferingreduceddrillingcycletime,reducedmaintenancetodrillingsystems,reduceddroppedobjecthazards,reducedsafetyriskresultinginreducedshut-inandstart-upofproducingwells,simultaneousdrillingandproductionoperationswithreducedrisk.
TheSpotlightonNewTechnologyAwards,whichareforOTCexhibitors,showcasethelatestandmostadvancedhardwareandsoftwaretechnologiesthatareleadingtheindustryintothefuture.Speakingofthisyear’swinnersSpotlightAwardCommitteeChairHelgeHoveHaldorsensaid“ItisthankstothemthatoffshoreE&Pwillcontinuetoplayakeyroleinsupplyingtheworldwithaffordableenergyinasustainablemanner.”ItsumsupSBMOffshore’sethos.
SBMOffshoreandtheotherwinnersarehonouredinaspecialmulti-pagesectionoftheOTCconferenceprogram.Theawardwillbepresentedon6thMayintheRotundaareaoutsideofExhibitHallBintheReliantCenterduringtheconference.
Thisground-breakingtechnologywillhavebroadappealfortheindustrythankstothetimeandcostreductionachievedwhiledrillingmultiplewellsfromasinglesite,particularlywhencomparedtocurrenttechnology,whichrequiresthedrillingrisertoberecoveredandredeployedmultipletimes.
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One-Stop-Shop at SBM
for Semi-submersible and
Tension Leg Platform technology
SBM Offshore / Currents 16
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SBM Offshore / Currents 17
AtSBMOffshore,werisetothechallengesandstrivetowardsourgoaloffast
becomingthetrustedpartnerofchoiceinthedevelopmentofcompleteoffshorefloatingsolutionsfortheworld’senergycompanies.OurcompetenceinFPSOsiswell-knownhoweverourexpertisealsocoversotherneeds.NotallsituationsareperfectlyadaptedtoanFPSOvesselandcontractingadrillingMODUisoftenanexpensiveoption,hencewhyweofferseveraldiversesolutions.OurGrouphasaproductportfoliothatcanofferarangeofotherfloatingproductionoptionsdevelopedusingourin-houseengineering,procurementandprojectmanagementcapabilities.
Certainsystemsneedtoaccommodatespecificweatherconditionsandharshenvironmentsforoperations.Inaddition,majorplayersareexploringdeeperandmoreremotewaters–sometimes200ormoremilesoffshore-wherenoexportpipelineinfra-structureexists.
Withsomanyfactorsinvolvedinthedecisiontodevelopafielditcanfeellikeanobstaclecoursetoclientswhenchoosingtherightstrategytomoveforwardinanefficientandeconomicalmanner.ForsomefieldsacombinationofeitheraTLPorasemi-submersibleincombinationwithanFPSOistheidealsolutionastheFPSOcanbeanchorednearbyadrytreewellheadunitforprocessingandstoragepurposes.WeareseeingthisoptionnowbeingusedinWestAfricaandinBrazil.
Elementstobeconsideredincludewhetherthefieldhasshort-termorlongtermpotential,full-fieldorphaseddevelopment,flowassuranceandexportmode
(pipelineorshuttle-tankers)andasmentionedweatherconditions. ThebeautyaboutSBMOffshoreisthatweofferall-encompassingsolutions.ClientscanturntoSBMforafullyintegratedcombinedsolutionofwellheadunitandFPSOeliminatingthecomplexinterfacestobemanagedbetweenthetwofloatinginstallations.
Semi-submersible technology
Intheearly1970’s,semi-submersiblesbegantobeusedasfloatingproductionplatformsforproductionfromsubseawells.However,theweaknessintheseearlysystemswastheavailablerisersystemstoproduceoiland
gasfromsubseawells,aswellasforoilandgasexport.Earlysystemsfirstusedtop-tensionedrisers,whichthenevolvedintoflexiblecatenaryrisersystems.Then,inthe1990’s,thefirststeelcatenaryriser(SCR)systemwasinstalledfromaTLP,providingamuchcheaperandgenerallymorerobustrisersystemthanflexiblepipe,butonewhichwasmoresensitivetovesselmotions.Foranumberofyears,semisubmersibleproductionplatformscontinuedtobedevelopedwithflexiblerisersbecauseofthelargermotionsinherentintheseplatforms.
Withthebigplayersintheindustryhavingtoexploredeeperandmoredifficultwaters,theracewasontofindasolutiontoaccommodatetheirevolvingneeds.Focusingonwavemotionresponsecharacteristics,SBMOffshore’sengineeringteaminHoustondevelopedthenewgenerationsemi-submersiblecapableofsupportingtheuseofSCRsindeepwaterapplications.CalledtheDeepDraftSemi®,thisinherentlysafedesignwithitsrobusthullhashasquicklygainedwideacceptanceintheindustry.Weholdtherecordforthedeepestwaterdepthsemi-submersibleFloatingProductionUnit(FPU)intheworld:IndependenceHub,
whichwasinstalledin2007atadepthof2,469metresinMC920intheGulfofMexico(GoM)forEnterpriseProductsPartners.Thisfacilitysetmanyindustryfirstsin engineering designandconstruction,and
isequippedtoprocessgasfromtenfieldswithexcesspayloadcapacitytohandleanadditionaltenfields.AnotherexampleofSBM’sexcellenttrackrecordforthistypeofsemi-submersibleFPUistheThunderHawk,anotherDeepDraftSemi®whichisownedbySBMandleasedtoMurphyOil.ThunderHawkisalsooperatingintheharshhurricaneconditionsoftheGoMatawaterdepthof1,847m.FirstoilwasachievedinJuly2009,anditisequippedtoprocessbothoilandgasfromtheThunderHawkfield.Theproject’sscopeincludedprovidingfullEngineering,Procurement,ConstructionandInstallation(EPCI)servicesfortheTopsides,Hull,
The Thunder Hawk FPU was one of the first to address the new Gulf of Mexico environmental criteria which evolved from the Ivan, Katrina and Rita hurricane experiences
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SBM Offshore / Currents 18
Moorings,Installationandoffshorecommissioning.SBMHoustonalsoprovidedthedetailedsteelcatenaryriser(SCR)designandhelpeddevelopthewaveslamloadmethodologiesutilizedinthisproject.
AkeyfeatureoftheDeepDraftSemi®isitslowmotioncharacteristicstoaccommodatetherequirementsofSCRrisersinacost-effectivemannercomparedtootherFPUconcepts.Anothersignificantadvantageisthesystem’sabilitytomatethetopsidesdecktothehullatquayside,avoidingcostlyoffshoreliftingandsystemcommissioningoperations.Byintegratingthetopsidesontothehullatquayside,theFPUcanbefullypre-commissionedandUSCG‘QuartersHabitable’permitscanbeobtainedpriortomobilisingthefacilityoffshore–soreducingcostly,laborintensive,offshorecommissioningactivities.
TheDeepDraftDry-TreeSemiisalogicalextensionoftheDeepDraftSemi®.TheDeepDraftDry-TreeSemi-submersibleco-locatesthedrillingactivitiesandwellheadorproductionactivitiesonthesamevessel.Thesemi-submersiblemaintainsitsadvantagesofbeingadesirablerisersupportplatform,enablesquaysideintegrationandquaysidecommissioning.SignificantdesigneffortiscompleteforthemorebenignlocationssuchasoffthecoastofWestAfricaandBrazil.ModeltestsprovideSBMwithawealthofinformationwhichisusedtounderstandandtoimproveontheirdesignapproachforthemoreextremeenvironments.Presently,SBMisperformingaseriesofDeepDraftDry-Treesemi-submbersiblemodeltestsatLaboceanoinRiodeJaneiro,Brazil.Themodeltestprogramisfocused
aroundadrytreeunitslocatedin2,440metresofwaterandexposedtowaveconditionsrangingfrombenigntoextremehurricanes.Riserstrokeandtheeffectoftheriserguideonthemotionsaresomeofthekeyperformancecharacteristicstobeanalysed.
Tension Leg Platforms (TLPs)
SBM’sproductlineincludestheTLPproductsSeaStar®,FourStar®andFourStarXC.TheTLPproductlineprovideswetanddrytreesolutionsuptowaterdepthsof1,500to1,800metresforhurricaneandnon-hurricaneenvironments.SBMdesigned,built,andinstalledthefirstmini-TLP,thefirstEPCcontractorprovidedTLP,andthefirstsubseacompletionTLP.
SBM’sexperienceinTLPsincludesdevelopmentoftheSeaStarmono-columnmini-TLP,with5installedexamplesintheGoMfrom1998through2007inwaterdepthsupto1,300m.Theseareallsmallplatforms,withpayloads(equipment,deckstructure,risers)of4000to12,000tonnes.Forlargerpayloads,andforinstallationsinareaswithouttheinfrastructureavailableinGoM,SBMhasdevelopedseveral4columnTLPconfigurationswhichcanbescaleduptopayloadsof40,000tonnes,andareself-stablefortransportandinstallationwithallequipmentinstalledandcommissionedatquayside.
AkeyadvantageoftheTLPisthatthelargeverticalheavemotioniseliminatedresultinginshortstroketoptensionedrisersystemswhichgivessubstantialcostreductionsforthesesystemsversuslaterallymooredfloatingproductionsystemssuchasSpars.AsaresultTLPsprovideanidealsupportforrisersofalltypes.Anotherkeyadvantageisthecostsavings
relatedtodrillingandproductionhardwareandoperatingcostversuswettreesubseadrilling&productionhardwarecost.Dry-TreeTLP’sequippedwithTenderAssistedDrillingcapabilityorSelfContainedDrillingmodulesallowforthedrilling,work-overandwellinterventionactivitiestobeperformeddirectlyfromtheTLPtomultiplesubseawellsfromonboardtheTLPversuslongtermcontractingofaMobileOffshoreDrillingUnit(MODU)requiredtoperformdrilling,completions,wellinterventionandwork-overactivitiesrequiredforsubseacompletions.ADry-TreeTLPachievesthisdrillingandcompletionadvantagebyutilizinghighpressureTopTensionedDrilling&ProductionRisersconnecteddirectlytoeachofthesubseawellheadsandextendinguptotheTLPlowerproductiondeck,theriserissupportedbythedeckmountedproductionrisertensioningsystems.Thewellsaredrilledandcasedindividuallythroughahighpressuredrillingriserwithasurfaceblowoutpreventer(BOP),thewellisthensecuredtoallowdisconnectionofthedrillingriserinordertoinstallthehighpressureproductionriser.Oncetheproductionriserisinstalledthewellcanthenbeverticallyaccessedinordertoinstalltheproductiontubingsupportedbythesubseawellheadandsurfacewellheadinstalleddirectlyontotheupperendoftheproductionrisertensionjointwhichcanthenacceptthesurfaceproductiontree.Theproductionflow-lineandannulushighpressureflexiblejumpersaretheninstalledalongwiththesurfacetreecontrolumbilical.
AnotheradvantageistheTLP’ssmallfootprint,whichallowsittobeusedinconjunctionwithothermooredsystemsincloseproximitysuchasanFPSOorFSOconnected
SBM Offshore / Currents 18
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SBM Offshore / Currents 19
bycatenaryflow-linesorSBM’sGAPsubseapipelinesystem.InthisfielddevelopmentscenariotheTensionLegPlatformisutilisedasthewellheadplatformhencethetermTensionLegWellheadPlatform(TLWP)astheprocessingoftheproducedfluidoccursontheFPSOwhenstorageandoffloadingispreferredtoexporttopipelines.
SBM’sdevelopmentoftheFourStar®TLPandFourStarXCTLPwasbasedonexperiencewithboththeSeaStar®,andtheDeepDraftSemi®.TheobjectivewastoprovideanimprovementoverthetraditionalroundcolumnTLP,whileincorporatinglessonslearnedfromourotherprojects.Thenewplatformsweretobesimpletodesignandbuild,bescalablefromsmalltolargepayloads,havefullstabilityduringconstruction,transport,andinstallationphasesoftheproject,befullycommissionedatquayside,andincorporatethelessonslearnedfromworkingwithouroperatorsonperformance,marinesystemsdesign,operability,andmaintenance.
WhenevaluatingfielddevelopmentscenariosforaDry-Treesolutionthemaindriversare1)costofcontractingMODU’s,2)typeofreservoir(RecoveryFactor)3)typeofwellintervention,and4)numberofwells.Dry-Treeshavebeenwellproveninmaturefieldsandareatechnologywithwhichoperatorsfeelcomfortable.Inaddition,integrationandcommissioningatquayside,issaferandprotectedfromtheweatherelements,andthereistheabilitytoperformawettowofthecompletedDry-TreeUnit(DTU)tothefieldwhichispreferredbyoperatorstocompetitors’moreexpensiveandriskyoptionsthatrequireintegrationandcommissioningoffshore.
TheDry-TreeSemi-submersiblecomplementstheFPSOproductbyenablingintegratedsolutionswhendry-treesareneeded.
Definitions:
Semi-submersible
Afloatingunit,comprisingofcolumnsandpontoons.Thecolumnssupportthedeckwhilethepontoonsinterconnectthecolumnsbelowthewatersurface.Theopenspacinginbetweenthecolumnsmakestheunitmorecompliantwiththewaves.Stationkeepingforasemisubmersibleistypicallyprovidedbyamooringlineconfiguration–thepreferredsolutionforlongtermstationkeeping-orbyadynamicpositioningsystem.
Tension Leg Wellhead Platform (TLWP)
Afloatingproductionandordrillingplatformwherestationkeepingisprovidedbyverticaltensionelementscalledtendons.Thetendontensionisprovidedbyexcessbuoyancyofthehull.Subjectedtowave,windandcurrentaction,theplatformmoveslaterally,butremainshorizontalduetotheparallelactionsofthetendons.Theverticalmovement(heave)iseliminatedandthefacilityisthereforesuitableforsurfacecompletionofthewells.
SeaStar® - TLPdevelopedbySBMOffshore’sHoustonoffice,isthewellprovenexampleofaTLP,usingamono-columnstructureasopposedtomulti-column(typicallyfour).ThisTLPcanaccommodatewetordrytreedevelopmentuptopayloadsof11,000tonnesfordeepwaterdevelopments.
FourStar™ TLP - TLPdevelopedbySBMOffshore’sHoustonoffice,afour-columnTLPdesignthatsupportsfulldeepwaterdrillingand/orproductionriserpayloadsexceeding8,000tonnesandcanbescaleduptopayloadsof40,000tonnesThedesignallowsforefficientquaysideintegrationoftopsidesandhullsystemsandisself-stablefortransportandinstallationwithallequipmentinstalled.
SBM Offshore continually improves TLP and Semi-Sub solutions with state-of-the-art technological advances. Our OTC award-winning Drilling Riser Trip Saver™ is an innovative apparatus and method for drilling multiple subsea wells consecutively, which saves time, money and reduces risk by avoiding removal of the suspended drilling riser from the well bay. It uses a rail-mounted transport system, which relocates a suspended drilling riser with a drilling riser tensioner system and surface blowout preventer in-place. You can read more about this technology on page 14.
// Issue 8 // may 2013
Extending the operating envelope of large mooring systems
SBM Offshore / Currents 20
Manifold and gantry of the Skarv turret
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SBM Offshore / Currents 21
The market demand for turnkey mooring systems is strong, particularly for large,
complex turrets, often located in some of the world’s most severe offshore environments. These complex turrets present many technical challenges, and give us the opportunity to demonstrate our expertise as the world leader in mooring technology.
Atthetopendofthemarket,therequiredoperatingenvelopeofthesecomplexmooringsystemsiscontinuallybeingextended:deeperwater,moresevereweatherconditions,largervesselstobemoored,higherthroughputs,increasedpressuresandlongerdesignlives.Theintroductionofa10,000yearreturnperioddesigncaseisalsobecomingamorecommonrequirement,replacingthetraditionallowerreturnperiodsasthegoverningcaseforthedesign.
Complexityofaturretisdependentuponmanyfactors,butonesimpleindicatoristhediameteroftheturretchaintable,whichisaffectedbyboththemooringloadsresultingfrommetoceanconditionsandvesselsizeplusthenumberofrisers.Theaveragediameterhaseffectivelydoubledoverthelast20years,andSBMhasdeliveredturretswithdiametersupto25m.
Akeycomponentintheselargeturretdesignsisthebogiebearingsystem.Thissystemistheinterfacebetweenthegeostationaryturretandrotatingvessel,anditallowsthevesseltoweathervanearoundtheturretandadoptthepositionofleastresistancetotheprevailingweather.OurSBM’sbogiedesignwasinitiallydevelopedfromin-houseexperiencegaineddesigninglargecranebogiesystems,andwasfirstusedontheSchiehallionFPSOinthesevereenvironmentoftheAtlanticMargin.Thissystemhasnowoperatedfor15years,andthebogieshaveperformedtheirfunctionwithoutincident.
The development and continued
use of the bogie system is based
on its clear advantages over a
traditional roller bearing for large
turrets:
1. All components are above
water and inspectable
2. Individual bogie components
can be replaced while the FPSO is
operating
3. The individual units are
standard components with a
proven service history, and the
number of bogies used is selected
to match the loads that the
system will experience
Manifold section of the Skarv turret
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Tofurtherextendtheuseofthebogiesystemforextremeconditions,wehavedevelopedavariantoftheinternalturretdesignthatfeaturesasetof‘stoppers’nearthelevelofthevesselkeel.Innormaloperationthereisagapbetweenthestopperandtheturretcylinder,andallthemooringloadsaretransferredthroughthebogiesystem.Howeverinextremeconditions,theturretcylindercontactswiththestopper,andthestopperbecomestheloadpathforthesehighmooringloads.Becausethestoppersaresimpleandrobust,andonlyoccasionallyexperienceanyload,theydonotneedtobeinspected,andtheadvantagesofthebogiesystemarepreserved.ThisdesignwasfirstemployedfortheBP’sSkarvFPSOturret,andhas
sincebecomeastandardfeatureofourhighcapacityinternalturrets.
Inadditiontoincreasingmooringloadsonpermanentlymooredsystems,therehasalsobeenasteadyincreaseintheloaddemandondisconnectablesystems.Toaddressthischallenge,SBMhasdevelopedahighcapacityconnectorabletolockadisconnectablebuoyintoaninternalturret,andtobeabletoreleasethebuoyunderloadinlessthanasecond.Likethebogies,theconnectorisagenericdevice,andthenumberusedwillbematchedtotheloadrequirement.Thisgenericcomponenthasacapacityof900tonnesperconnectorwhenlocked,andcanreleasethebuoyundermorethan600tonnes.Bycombininganumberofconnectorsinthismanner,disconnectablesystemscannowbedesignedtobothstayconnectedandthendisconnectunderhigh
mooringloads.Thisopensthepossibilitiesofusingdisconnectablesystemsinicefields,andtowithstand100yearreturnperiodcyclonicconditions,whilstdisconnectingtoavoidthe10,000yearcasewhichmayotherwisegovernthestrengthrequirementsofthemooring,hullandtopsidesstructure.
Inparalleltoincreasingmooringloads,therequirements
forthroughputandpressureofincomingfluidsarealsoincreasing.Thisisthedriver
behindSBMOffshore’scontinuingdevelopmentprogrammetoqualifybothhigherpressureandlargerdiameterswivels.ThequalificationoftheseswivelsisperformedintheSBMlaboratoryinCarros,France,whereweareclosetocompletingthetestprogrammetoqualifyan800bartoroïdalswivel.
AspartofSBM’scommitmenttostayingattheleadingedgeofswiveldesign,anHVACelectricalswivelhasalsobeenqualified,winninganOTCSpotlightonTechnologyawardin2011forthisdevelopment.
Manyofthedevelopmentsaimedatlargeturrets,andthelessonslearntexecutingtheseprojects,havealsobroughtbenefitstothedesignofmid-scalemooringsystems.Forexample,diverlesschainconnectssuchastheARCA(designedtoallowchange-outofthearticulationforsystemswithlongdesignlives),ortheIn-LineMooringConnector(theILMC,developedtomovethetensioningmeansfromthemooringsystemtoaninstallationvessel),bothbringbenefitsinsafety,andresultinamorecompactturretdesign.ResearchanddevelopmentonswivelsealperformancealsobringsbenefitstoswivelsonallofSBMOffshore’sweathervaningsystems.
Wearecommittedtocontinuingourdevelopmentprogrammeformoorings,andindevelopingworldclasstechnologythatwillsatisfyevolvingdemands.Byworkingcloselywithclientstoensureanunderstandingoftheirneeds,thecompanywillcontinuetopushtheboundariesofmooringtechnology,andtodeliverthemooringsystemsofthefuture.
SBM Offshore / Currents 22
Quad 204 turret
// ISSuE 8 // MAY 2013
TheSBMlaboratoryhasalwaysbeenakeyfactorinourabilitytostayattheforefrontofmooringtechnology.Beingabletoprototypeandqualifyourproductsin-housegivesusamajoradvantageoverourcompetition,andtheworkofthelabhasbeenfundamentalinthesuccessfuldevelopmentofourhighpressurefluidswivels,MAGanchors,HVACswivel,cryogenicswivelsandLNGoffloadinghoses.
ThelabwasoriginallyestablishedinStLaurentduVarinFrancein1989aftertheacquisitionoftestrigsfromEMH.In2004itrelocatednearbytothepresentlargerpremisesinCarros,France,whichprovidesatotalareaof1100m2,includinganindoorhallof600m2whichhousesmostofthecomplextestrigs.Monitoringtoolssuchasvideoextensometers,photogrammetryequipment,andhighspeedandinfra-redcamerasareavailableaspartofthelab’sstandardequipment,andpartnershipswithexternalorganisationssuchastheUniversityofNicealsogivesusaccesstotomography,goniometricsandotheradvancedmonitoringandanalyticaltechniques.
SBM Offshore / Currents 23Assembly of test swivel
Test facilities at the SBM lab
ISSue 8 // May 2013
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